Elastic warp-knit fabric

ABSTRACT

A fabric article useful for the cushioning surface of a car seat and like items is formed from thick main elastic yarn which is thicker than main stitch yarn, and main inserted yarn which is more bulky and thicker than the main elastic yarn in apparent thickness, are knitted in line in the knitting width direction or in the knitting length direction of a mesh-like base knitted fabric which is knitted up with main stitch yarns by using a warp knitting machine and which have openings which are larger than the needle loops formed from the stitch yarn and extend over plural knitting courses.

FIELD OF THE INVENTION

The present invention relates to an air-permeable warp knitted elasticmesh fabric which is used to form a cushioning surface of a body supportsuch as a legless-chair, single-chair, bench, seat-backrest,seat-footrest, car-seat, sofa, bed and the like, which is used toelastically support a body indoors, outdoors or inside of a car, bystretching (hanging) the fabric between frame parts of a frame.

BACKGROUND OF THE INVENTION

As disclosed in Japanese Patent Laid Open No. 11-279906, JapaneseUtility Model Laid Open No. 56-103080 and Japanese Utility Model LaidOpen No. 54-139779, warp knitted elastic mesh fabrics having openings,each of which is larger than a needle loop formed from the stitch yarnextending over plural knitting courses, are well known.

As disclosed in Japanese Patent Laid Open No. 11-279907 and JapaneseUtility Model Publication No. 3-36555, weft inserted warp knittedfabrics having inserted yarns, which are knitted into a base knittedfabric formed from main stitch yarns by a warp knitting machine andwhich are in continuous in line in the knitting width direction, andwarp inserted warp knitted fabrics having inserted yarns, which areknitted into base knitted fabric formed from main stitch yarns by a warpknitting machine and are in continuous line in the knitting lengthdirection, are well known.

As disclosed in Japanese Patent Laid Open No. 11-279907, Japanese PatentNo. 3096356 and Japanese Patent Gazette 62-60489, the knitting method ofthreading an elastic yarn into warp knitted fabrics is well known.

As disclosed in Japanese Patent No. 3096356, 11-279907, polyether-esterelastic yarn is well known as the elastic yarn to be threaded into warpknitted fabrics.

It is known to apply a woven elastic fabric, on which surface ahoney-comb pattern was drawn with a leno and gauze textile design, tothe cushioning surface of the car-seat and the like. The leno and gauzetextile design may be woven in a manner where monofilament elastic yarnsof a fineness of about 2000 dtex are applied to warp yarns and,multifilament bulky texturized yarns having an apparent thickness whichis thicker than the monofilament elastic yarns are applied to weftyarns, warp yarns arranged in the weaving width direction are classifiedinto 8 groups, open sheds are formed by each pair of adjacent warp yarnsof each group, the shedding motion (open shed) is changed every picking,and two weft yarns which are picked into the open shed in order are tiedup by the pair of adjacent warp yarns (FIG. 5).

In the case of application of the warp knitted mesh fabric to thecushioning surface of the car-seat, the cushioning surface which hasgood air-permeability, and gives a cool feeling to touch, and does notgive a warm sticky feeling, may be obtained. However, conventional warpknitted mesh fabric applied to the cushioning surface can not bear up inuse, since loosened puckers arise and a recess (sagging) appears overthe cushioning surface in use.

In this connection, in the case of the application of the weft insertedwarp knitted fabrics, where the elastic yarn is threaded in, and thewarp inserted warp knitted fabrics, where the elastic yarn is threadedin, to the cushioning surface, loosened puckers and recesses or saggingmay be avoided by the elastic yarn and a durable car-seat or the likemay be obtained.

For this purpose, it is necessary to densely thread the monofilamentelastic yarns of single fiber fineness of more than 1500 dtex into thebase knitted fabric so that stress at 10% elongation in the directionwhere the elastic yarn may be continuous in the warp knitted fabric ismore than 100 N/5 cm.

However, in the case of application of such a thick monofilament elasticyarn, the surface of the warp knitted fabric becomes similar to themonotonous simple surface of the conventional plastic sheet goods. Sothat a car-seat or a like article having high market value can not beobtained. Since the surface of the monofilament elastic yarn, which isthick in single fiber fineness, is flat and slippery like the surface offishline, so that a soft and quite natural fine appearance, which iscovered with fine fibers, can not be formed over the surface of the warpknitted fabric.

The surface of woven elastic fabric, where thick monofilament elasticyarns are densely woven in and exposed over the surface of woven elasticfabric like a mat rush of facing tatami mats, is flat, slippery, andglossy, so that, when limbs are put on the cushioning surface formedfrom such an elastic fabric, limbs will slip, and can not be maintainedin a comfortable posture producing a feeling of fatigue.

The woven elastic fabric woven on which surface a honey-comb pattern isdrawn out is lacking in size and shape stability, so that a cushioningsurface of high durability can not be formed. Since the honey-combpattern is formed with weft yarns which are in a tortuous path in azigzag manner in the weaving width direction, when tension acts in theweaving width direction, these weft yarns are elongated and transformedin line.

Therefore, the present invention intends to provide an improved warpknitted elastic fabric which is useful for the cushioning surface of acar-seat and the like, and has the following properties: it does notcause a recess and loosened pucker resulting from load-hysteresisfatigue in use for the cushioning surface; it has high dimensionalstability; it does not cause a distortion of stitch openings; it hashigh air-permeability; it does not give a warm sticky feeling; it isable to maintain limbs of the user in comfortable posture withoutslippage when limbs are put on the cushioning surface; it has a softfeeling when touched; it is not glossy; it has a soft and a quitenatural fine appearance covered with fine fibers; it is not similar tothe monotonous simple surface of the conventional plastic goods inappearance; and it has a high market value.

SUMMARY OF THE INVENTION

A warp knitted elastic fabric, in accordance with the present invention,has a first characteristic comprised of the following elements (1), (2),(3) and (4).

(Element 1)

A base knitted fabric (10) is knitted up from main stitch yarns by usinga warp knitting machine.

(Element 2)

Main elastic yarns (14) are knitted in the base knitted fabric (10) andare in continuous in line in the knitting width direction (C) or in theknitting length direction (W).

(Element 3)

Main inserted yarns (15) are knitted in the base knitted fabric (10) andare in continuous in line in the knitting width direction (C) or in theknitting length direction (W).

(Element 4)

Main inserted yarns (15) are more bulky than both main elastic yarns(14) and main stitch yarns, and main inserted yarns (15) are thicker inapparent thickness than both main elastic yarns (14) and main stitchyarns.

The warp knitted elastic fabric does not produce a monotonous simpleimagine similar to plastic goods since a flatness and glossy appearanceof the surface is restrained by the light absorption of the maininserted yarns (15) of which surface is made from countless fibers andhas low light reflection.

And, the knitted elastic fabric has a very soft feeling when touched andis useful for the cushioning surface of a car-seat and a like, since themain inserted yarns (15) are thick in apparent thickness and very bulkyand the countless fluff and pile fibers of the surface of the maininserted yarns are to be projected between adjacent sinker loops (18,18)of the main stitch yarn and are not depressed and covered with thesinker loops (18,18) of the main stitch yarn.

In addition to the first characteristic set forth above, the warpknitted elastic fabric, in accordance with the present invention, hasthe second characteristic comprised of the following elements (1) and(2).

(Element 1)

On the base knitted fabric (10), there are openings (16) which arelarger than the needle loop (17) formed from the main stitch yarn andwhich extend over plural knitting courses.

(Element 2)

The base knitted fabric (10) is formed as a mesh.

The surface of the main inserted yarn (15) is covered with countlessfibers and lacks light reflection.

Thus, the surface gloss and flatness of the fabric is restrained by thelight absorption of the main inserted yarns (15).

In addition, the fine shape of an opening (16) acts to disrupt anoccurrence of surface gloss.

Thus, the warp knitted elastic fabric has a quite natural appearance andhigh air-permeability and cool touch feeling, and does not have amonotonous simple imagine similarly to sheet plastic goods, and becomeseasy to mould by fitting to the configuration of the frame (23) of thecar-seat and the like.

In addition to the characteristics of the first and the second, the warpknitted elastic fabric, in accordance with the present invention, hasthe tenth characteristic comprised of the following element (1).

(Element 1)

The main inserted yarn (15) is chenille yarn which is formed with axisyarns and pile fibers for covering the axis yarns wherein the pilefibers are projecting from the axis yarns.

Since the pile fibers of the main inserted yarn (chenille yarn 15) areprojecting and covering the surface of the warp knitted elastic fabricand effect non-slip action, limbs resting on the cushioning surface (24)are not in slippage but supported in comfortable posture, and the pilefibers have a comfortable feeling when touched. Because of theseproperties, the warp knitted elastic fabric becomes suitable for thecushioning surface.

In addition to any one of the above characteristics of the first thesecond and the third, the warp knitted elastic fabric, in accordancewith the present invention, has a sixth characteristic comprised of thefollowing element (1).

(Element 1)

The main stitch yarn is a thermo-adhesive sheath/core combination ofpolyether-ester yarn which is made of polyether-ester applied to a corecomponent polymer and thermo-adhesive polymer having a melting pointwhich is lower than core component polymer, applied to the sheathcomponent polymer.

When this warp knitted elastic fabric is finished up by passing througha dry-heating treatment, the main elastic yarn and the main stitch yarnare thermally adhered. Then, the warp knitted elastic fabric which doesnot cause distortion of stitch openings under reiterative stretching,and which is rich in abrasion resistance and dimensional stability, andwhich is useful for the cushioning surface, can be obtained.

In addition to any one of the above characteristics of the first, thesecond, the third and the fourth, the warp knitted elastic fabric, inaccordance with the present invention, has the twelfth characteristiccomprised of the following element (1).

(Element 1)

The main elastic yarn (14) is a thermo-adhesive sheath/core combinationpolyether-ester elastic yarn which is made of elastic polyether-esterapplied to a core component polymer and thermo-adhesive polymer having amelting point lower than the core component polymer applied to thesheath component polymer.

As mentioned above, when this warp knitted elastic fabric is finished upby passing through dry-heating treatment, the main elastic yarn and themain stitch yarn are thermally adhered. Then, the warp knitted elasticfabric, which does not cause distortion of stitch openings underreiterative stretching, and which is rich in abrasion resistance anddimensional stability, and which is useful for the cushioning surface,can be obtained.

In addition to any one of the above characteristics of the first throughthe fifth, the warp knitted elastic fabric, in accordance with thepresent invention, has the thirteenth characteristic comprised of thefollowing element (1).

(Element 1)

The fineness of the plurality of the main elastic yarns (14) which isincluded within the unit distance (1 cm) in the knitting lengthdirection (W) or in the knitting width direction (C) should be more than7000 dtex/cm.

This warp knitted elastic fabric is improved when it is applied to thecushioning surface (24) by stretching and hanging over the frame (23).Sagging and loosened pucker do not arise under repeated loading due tolimbs or body weight, and it is highly durable and becomes suitable forthe cushioning surface (24).

In addition to any one of the above first through sixth characteristics,the warp knitted elastic fabric, in accordance with the presentinvention, has the ninth characteristic comprised of the followingelement (1).

(Element 1)

The main elastic yarn (14) and the main inserted yarn (15) are knittedin respectively the different course of the base knitted fabric (10).

In this case, the main elastic yarn (14) and the main inserted yarn (15)are set apart from one another by the needle loop (17) and the sinkerloop (18) of the main stitch yarn and are aligned in parallel with oneanother.

Because of this, in the application for the cushioning surface (24) ofthe frame (23) of the car-seat and the like, the main inserted yarn (15)does not touch with the stretchable main elastic yarn (14). Therefore,the main elastic yarn (14) can not be rubbed by the main inserted yarn(15), so that it does not wear out easily. And, stretching actions ofthe main elastic yarn (14) are not interfered with by the main insertedyarn (15). Thus, the warp knitted elastic fabric has enhanced propertiesof stretchability and abrasion resistance and becomes suitable for thecushioning surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a warp knitted elastic fabric on a knittingprocess in accordance with the present invention.

FIG. 2 is a perspective view of a seat wherein a fabric is hanged over.

FIG. 3 is a schematic view of a knitting textile design of a warpknitted elastic fabric made in accordance with the present invention.

FIG. 4 is a plan view of a warp knitted elastic fabric made inaccordance with the present invention.

FIG. 5 is a plan view of a conventional woven elastic fabric.

DETAILED DESCRIPTION OF THE INVENTION

As mentioned above, weft inserted warp knitted fabrics having insertedyarns knitted into the base knitted fabric (10) in line in the knittingwidth direction (C) and warp inserted warp knitted fabrics havinginserted yarns knitted into the base knitted fabric (10) in line in theknitting length direction (W) are well known as disclosed in JapanesePatent Laid Open No. 11-279907 and Japanese Utility Model PublicationNo. 3-36555.

Conventional raschel warp knitting machines having a weft yarn insertapparatus or a warp yarn insert apparatus can be applied to knit up thewarp knitted elastic fabric in accordance with the present invention.

A reason to knit the main elastic yarn (14) into the base knitted fabricis to increase the cushioning property and dimensional stability of thebase knitted fabric and is to restrain occurrence of recessing orsagging and loosened pucker on the cushioning surface of the car-seatand the like during use.

For this purpose, it is desirable to apply a thick monofilament elasticyarn of breaking elongation more than 60% having a rate of elasticrecovery after 30% elongation of more than 90% single fiber fineness of1000˜4000 dtex, preferrably 1650˜2750 dtex, further preferably 2000˜2500dtex, and of which stress 10% elongation is more than 0.1 cN/dtex,preferably 0.2˜8 cN/dtex, to the main elastic yarn (14).

The main elastic yarn (14) is knitted into the base knitted fabric (10)so that stress (F) at 10% elongation of the warp knitted elastic fabricin the knitting length or width direction where the main elastic yarn(14) is in continuous in line is between 150˜600 (cN/dtex)(150≦F≦600).

For that the stress (F: N/5 cm) at 10% elongation of the warp knittedelastic fabric is between 150˜600 (N/5 cm), it is desirable to maintainthe sum (total) fineness of a plurality of the main elastic yarns (14),which is included within the unit distance (1 cm) in the knitting lengthdirection or in the knitting width direction at more than 7000 dtex/cm.

Polyester elastic yarn, polyurethane elastic yarn and polyether-esterelastic yarn are well known as high elastic yarns which have a high rateof elastic recovery in connection with elongated strain (elongation).

Among them, polyether-ester elastic yarn is most suitable for thepresent invention because stress at 10% elongation of polyester elasticyarn is about 2.2 (cN/dtex) and strongest of all.

Stress at 10% elongation of polyether-ester elastic yarn is about 0.27(cN/dtex).

Stress at 10% elongation of polyurethane elastic yarn is about 0.015(cN/dtex) the weakest of all.

By the way, as shown in FIG. 2, the present invention relates to thewarp knitted elastic fabric (20) to be applied to the cushioning surface(24) by stretching and hanging over the frame (23).

For the warp knitted elastic fabric (20) used as materials of cushioningsurface (24), when polyurethane elastic yarn is applied in place ofpolyether-ester elastic yarn, since polyurethane elastic yarn issubstantially weaker than polyether-ester elastic yarn, a part of thecushioning surface (24) deeply sags and moves to and fro due to theweight of limbs and the limbs are not stably supported.

On the other hand, when polyester elastic yarn is applied in place ofpolyether-ester elastic yarn, since polyester elastic yarn isextraordinarily stronger than polyether-ester elastic yarn, though apart of the cushioning surface (24) does not deeply sag, the cushioningsurface (24) which is formed is hard, and it effects an uncomfortabletouch feeling that it can not help to keep limbs on the cushioningsurface in use.

And, in the case of application of weak and elongatable polyurethaneelastic yarn, irregularity of tension tends to arise in the warp knittedelastic fabric at a time of stretching and hanging it over the frame(23).

On the other hand, in the case of application of strong andunelongatable polyester elastic yarn, pucker tends to arise over thewarp knitted elastic fabric at a time of stretching and hanging it overthe frame (23). And, bentpucker and other irregular distortions, whicharise over the warp knitted elastic fabric before application to thecushioning surface, can not be easily cured by the way of stretching orexpanding it.

Further, in the case of application of weak and elongatable polyurethaneelastic yarn, irregularity of tension among the stitch yarns tends toarise in the knitting process, and the irregularity of tension among thestitch yarns makes the knitting process difficult. And, in the case ofthe application of strong and unelongatable polyester elastic yarn, itbecomes difficult to knit up the warp knitted elastic fabric, since inthe knitting process the strong and unelongatable polyester elastic yarndoes not easily vary its shape in cooperation with works or actions ofthe reed guide, the knit needle and other parts of the knittingapparatus.

In consideration of these matters, it is advantageous to usepolyether-ester elastic yarn of which stress at 10% elongation isextraordinarily stronger than polyurethane elastic yarn in the mainelastic yarn and main stitch yarn.

The reason for knitting the main inserted yarn (15) into the baseknitted fabric is that the flatness, the slipperiness, and the surfacegloss of the warp knitted elastic fabric (20), which may be effected bythick flat and glossy monofilament elastic yarn (main elastic yarn 14)which is thick like a fishline and has flat and very glossy surface, isrestrained by the main inserted yarn (15). Another reason for use of themain inserted yarn (15) is that the soft fine and quite naturalappearance of the warp knitted elastic fabric (20) as one kind of warpknitted fabric are maintained by the main inserted yarn (15) so itshould not be disturbed by the monofilament elastic yarn (main elasticyarn 14) and should not become similar to the monotonous simple surfaceof the conventional plastic goods.

Accordingly, multi-fiber yarn of which the surface is composed ofmultiple fibers in bulk and lacking in surface gloss is applied to themain inserted yarn. In this case, spun yarn, multifilament bulkytexturized yarn, chenille yarn and the like may be preferably used asmulti-fiber yarn. The multi-fiber yarn (main inserted yarn 15) isknitted into the base knitted fabric (10) with density of insertion,that is, rate of number (threads) of the main inserted yarns (15) versusregular interval (1 cm) where the main inserted yarns are arranged inparallel with one another toward the orthogonal direction which is atright angles to the prolonging direction where the inserted yarnsprolong, of more than 1 (threads/cm), preferably more than 2(threads/cm), or the multi-fiber yarn (main inserted yarn 15) is knittedinto the base knitted fabric (10) with rate of insertion of more than 1(1 thread) of the main inserted yarn (15) versus 7 (7 thread) of themain elastic yarn (14) (that is, more than 1:7), preferably more than 1(1 thread) of the main inserted yarn (15) versus 4 (4 thread) of themain elastic yarns (14) (that is, more than 1:4).

Total fineness of the main inserted yarns (15) may be set up 1000˜5000dtex, preferably 2000˜4000 dtex.

In the present invention, main elastic yarn of 1000˜4000 (dtex) and maininserted yarn of 1000˜5000 (dtex) may be used.

These yarns (14,15) do not disturb the knitting process of the warpknitted elastic fabric, since these yarns (14,15) are different from themain stitch yarn (11,12,13) which form the base knitted fabric (10).That is, these yarns (14,15) are to be inserted and knitted in betweenneedle loops and sinker loops (17,18) in a manner where these yarns(14,15) are arranged in parallel with one another without forming aneedle loop and a sinker loop.

Preferably, main inserted yarn (15) is a chenille yarn which is bulky,which is made by covering axis yarns with countless pile fibers andthick in apparent thickness.

The chenille yarn may be any one of fancy yarn which is formed bytwining decorative yarns to core-yarns and by binding the decorativeyarns and the core-yarns with bind yarns to form pile fibers with thedecorative yarns, so called chenille yarn which is formed by putting cutpieces of pile fiber between axis yarns and by twisting the axis yarnsto fix the cut pieces between the axis yarns, and flocky yarn which isformed by electrostatically fixing pile fibers to axis yarn.

In the case of the fancy yarn, it is desirable to apply athermo-adhesive yarn (for example: the product Torey Co. Ltd. of Japan,sold under the trade name “Erder”) to the binding yarn to thermallyadhere and fix the decorative yarn to the core-yarns through the bindingyarns.

The main stitch yarns are composed of at least two kinds of the firstmain stitch yarn (11) and the second main stitch yarn (12).

The base knitted fabric (10) is knitted up in a manner where the firstmain stitch yarns (11) are applied to form chain stitched rows (19)which are continuous in the knitting length direction (W), the secondmain stitch yarns (12) are applied to form needle loops (17 b) which arecombined in one united needle loop with the needle loop (17 a) of thefirst main stitch yarn (11), and the second main stitch yarns (12) arealso applied to connect adjacent chain stitched rows (19 a,19 b) ofadjacent first main stitch yarns (11,11) shifting laterally between theadjacent chain stitched rows (19 a,19 b).

Reasons to knit up the base knitted fabric (10) in the above manner areexplained as follows.

That is, in the case of warp inserted warp knitted fabrics where themain elastic yarn and the main inserted yarn are knitted in the knittinglength direction (W), since the main elastic yarns (14) and the maininserted yarns (15) are to be aligned in parallel with the chainstitched row (19) of the first main stitch yarn (11), it becomes easy toknit in the main elastic yarns (14) and the main inserted yarns (15)into the base knitted fabric (10).

And, in the case of weft inserted warp knitted fabrics where the mainelastic yarn and the main inserted yarn are knitted in the knittingwidth direction (C), strength in the knitting length direction (W) isensured by the chain stitched rows of the first main stitch yarncorresponding to strength in the knitting length direction (W) where thefabrics are reinforced by the main elastic yarns and the main insertedyarn.

It is desirable to combine the main stitch yarns with at least threekinds of stitch yarn of the first main stitch yarns (11), the secondmain stitch yarns (12) and the third main stitch yarns (13).

In this case, the first main stitch yarns (11) form chain stitched rows(19) which are continuous in the knitting length direction (W), and thesecond main stitch yarns (12) and the third main stitch yarns (13) areapplied to bind and reinforce the adjacent chain stitched rows (19 a,19b) of adjacent first main stitch yarns over several courses.

Further, the second main stitch yarns (12) and the third main stitchyarns (13) are applied to bind and reinforce the adjacent chain stitchedrows formed from respectively different first main stitch yarns (11)over several courses in a manner where the second main stitch yarns (12)and the third main stitch yarns (13) are respectively shifted laterallyone wale in the opposite direction, that is, to shift between theadjacent chain stitched rows (19 a,19 b), by changing shifting directionevery course.

Thereby, the opening which is enclosed by reinforced left and rightchain stitched rows in the knitting width direction (C) and reinforcedfront and rear chain stitched rows in the knitting length direction (W)is formed.

Further, for improvement of strength and dimensional stability of thewarp knitted elastic fabric, thermo-adhesive sheath/core combinationpolyether-ester elastic yarn which is made of polyether-ester applied toa core component polymer and thermo-adhesive polymer having a meltingpoint lower than the core component polymer, is applied to at leasteither of the main elastic yarn (14) and the main stitch yarn,preferably at least either of the main elastic yarn (14) and the firstmain stitch yarn (11).

And, heat treatment is applied to the warp knitted elastic fabric afterthe knitting process to thermally adhere the main elastic yarn and mainstitch yarn.

Thereby, the needle loop and sinker loop of the base knitted fabric arefinished up dimensionally stable.

In this way, the main elastic yarn and the main inserted yarn are fixedto the base knitted fabric, the distortion of stitch openings is.

As the thermo-adhesive sheath/core combination polyether-ester elasticyarn, “Dia-Flora” (product name of Toyobo Co. Ltd., fineness: 2080 dtex)is well known.

Total fineness of the main stitch yarn may be set up less than one halfof total fineness of the main elastic yarn, preferably less than onequarter of total fineness of the main elastic yarn, generally 100˜800dtex, preferably 300˜800 dtex.

In the case of application of a sheath/core combination filament elasticyarn, which is made of lower melting point polyether-ester elastomerapplied to sheath component part and higher melting pointpolyether-ester elastomer applied to core component part, for the firstmain stitch yarn (11), it is desirable to apply a polyestermultifilament yarn to the second main stitch yarn (12) and the thirdmain stitch yarn (13), because the polyester multifilament yarn iscompatible with the sheath/core combination filament elastic yarn inconnection with the polyester component, thus these yarns easilythermally adhere to one another.

When the polyether-ester elastic yarn is applied to the main elasticyarn, the dyeing process of the warp knitted elastic fabric may becarried out easily, either polyether-ester elastic yarn or polyestermultifilament yarn is applied to the first main stitch yarn, thepolyester multifilament yarn is applied to the second main stitch yarnand the third main stitch yarn, and also the polyester multifilamentyarn is applied to the main inserted yarn.

That is, in connection with the dyeing property, textile materials ofthe warp knitted elastic fabric is to be standardized.

For the sake of improvement of weathering fastness of the warp knittedelastic fabric, as one kind of pigment colored fibers, thepolyether-ester elastic yarn and the polyester multifilament yarn arespun by adding a pigment to the spinning polymer and, if necessary,treated in the dyeing process.

In the case of application of pigment colored polyether-ester elasticyarn and pigment colored polyester multifilament yarn, the dyeingprocess of the warp knitted elastic fabric is thus carried out moreefficiently.

At the inside of the warp knitted elastic fabric, the main elastic yarn(14) is set in a hard stretching situation since it is in parallel withthe inelastic main inserted yarn (15) and its stretching elasticity isrestrained or limited by this inelastic main inserted yarn (15).

To avoid such restraint, it is desirable to apply high heat shrinkableelastic yarn, which is more shrinkable than the main inserted yarn, tothe main elastic yarn and to heat shrink the main elastic yarn at thetime finish treatment of the process or dyeing process for the warpknitted elastic fabric.

As a result, the inelastic main inserted yarn becomes loosened on theorder of the shrinking amount of the main elastic yarn, and theinelastic main inserted yarn is able to follow the stretching of themain elastic yarn. In other words, stretching elasticity of the mainelastic yarn is not restrained or limited by the inelastic main insertedyarn within the scope of shrinking amount of the main elastic yarn.Then, the warp knitted elastic fabric which is useful for the cushioningsurface (24) of a car-seat and the like can be obtained.

Heat shrinking rate of the main elastic yarn may be 10˜50%.

It is desirable to apply elastic yarn, which has elasticityapproximately equal to the main elastic yarn, orpolytrimethyleneterephthalate multifilament yarn, which has a highstretching property, to the axis yarn of the chenille yarn so that themain inserted yarn (chenille yarn) is able to follow the stretching ofthe main elastic yarn.

It is desirable to set up the gauge of the raschel warp knittingmachine, in connection with total fineness of the main stitch yarn, themain elastic yarn and the main inserted yarn, 5.5 gauge/cm (14gauge/inch) or 9.5 gauge/cm (24 gauge/inch).

In this case, wale density of the warp knitted elastic fabric may be setup 20˜40 (wale/25.4 cm), and course density of the warp knitted elasticfabric may be set up 15˜40 (course/25.4 cm).

FIG. 1 is a plan view of a warp knitted elastic fabric knitting processin accordance with the embodiment of the present invention.

FIG. 4 is a plan view of a warp knitted elastic fabric in accordancewith the embodiment of the present invention.

FIG. 3 is a schematic view of a knitting textile design of the warpknitted elastic fabrics of FIGS. 1 and 4, in accordance with theembodiment of the present invention.

The main stitch yarns are composed of the first main stitch yarns, thesecond main stitch yarns and the third main stitch yarns.

Polyether-ester monofilament elastic yarn (fineness: 300 dtex) is usedfor the first main stitch yarn (11).

Polyester multifilament yarn (total fineness: 500 dtex) is used for thesecond main stitch yarn (12) and the third main stitch yarn (13).

Polyether-ester monofilament elastic yarn (fineness: 2500 dtex) is usedfor the main elastic yarn (14).

Chenille yarn is used for the main inserted yarn (15).

This chenille yarn is formed by applying a polytrimethyleneterephthalatemultifilament yarn (total fineness: 150 dtex) to a core-yarn, by twiningpolyester multifilament bulky texturized yarn (total fineness: 150 dtex)around the core-yarn with overfeeding rate of 200%, and by twiningthermo-adhesive yarn (total fineness: 150 dtex, product name of ToreyCo. Ltd. “Erder”) to thermally adhere and fix the polyestermultifilament bulky texturized yarn to the core-yarn.

A single raschel warp knitting machine, which has a weft yarn insertapparatus and three reeds (L₁), (L₂) and (L₃) (each 24 gauge/25.4 mm),is used to knit up a warp knitted elastic fabric (20).

The first main stitch yarns (11) are guided and knitted in by the firstreed (L₁). The second main stitch yarns (12) are guided and knitted inby the second reed (L₂). The third main stitch yarns (13) are guided andknitted in by the third reed (L₃).

As shown in FIG. 3, the first reed (L₁) is knitted with a movement of0-1/1-0/0-1/1-0/0-1/1-0/ for formation of one-in-one-out knittingtextile design.

The second reed (L₂) is knitted with a movement of1-0/2-3/4-5/3-2/4-5/3-2/4-5/3-2/1-0/2-3/1-0/ for formation of theknitting textile design.

The third reed (L₃) is knitted with a movement of4-5/3-2/1-0/2-3/1-0/2-3/1-0/2-3/4-5/3-2/4-5/3-2/ for formation of theknitting textile design.

In this manner, the base knitted fabric (10) of 12 course/l repeat isknitted up.

In this knitting process, the main inserted yarns (15) are inserted andknitted into the first course (C₁) and the second course (C₂) of theknitting textile design shown in FIG. 3.

After that, the main elastic yarns (14) are inserted and knitted intothe third course (C₃), the fourth course (C₄), the fifth course (C₅) andthe sixth course (C₆) of the knitting textile design.

After that, the main inserted yarns (15) are inserted and knitted againinto the seventh course (C₇) and the eighth course (C₈) of the knittingtextile design.

After that, the main elastic yarns (14) are inserted and knitted againinto the ninth course (C₉), the tenth course (C₁₀), the eleventh course(C₁₁) and the twelfth course (C₁₂) of the knitting textile design.

In this manner, the main elastic yarns (14) and the main inserted yarns(15) are knitted in the base knitted fabrics (10).

As shown in FIG. 1, the sinker loops (18), which are formed from themain stitch yarn, are penetrated by the main elastic yarns (14) and themain inserted yarns (15) which are knitted in the base knitted fabric(10).

The loop-shaped needle loop (17) exists over one side of the mainelastic yarns and the main inserted yarns, that is, the rear side of thedrawing paper of FIG. 1.

On the other hand, over another side of the main elastic yarns and themain inserted yarns, that is, the surface side of the drawing paper ofFIG. 1, a part of arch-shaped sinker loop (18) exists.

As a result, the main elastic yarns (14) and the main inserted yarns(15) are exposed (appear) over one side of the base knitted fabric (10),that is, the surface side of the drawing paper of FIG. 1, where parts ofarch-shaped sinker loops (18) exist (appear), more than another side ofthe base knitted fabric (10), that is, the rear side of the drawingpaper of FIG. 1, where the loop-shaped needle loop (17) exist (appear).

As mentioned above, the main inserted yarns (15) should be applied torestrain or avoid gloss and flatness which are caused (effected) frommain elastic yarn (14) over the surface of the warp knitted elasticfabric (20).

So that, the warp knitted elastic fabric (20) is applied to thecushioning surface (24) of the car-seat or like article in a mannerwhere the sinker loop surface side (18), that is, the surface side ofthe drawing paper of FIG. 1, where the main inserted yarns (15) areexposed more, is faced to the out side, that is, the out side of thearticle.

In accordance with the present invention, the warp knitted elasticfabric which is useful for the cushioning surface of a car-seat and likearticles has the properties of resisting sagging and puckering resultingfrom load-hysteresis fatigue during use of the cushioning surface, hashigh dimensional stability and does not cause a distortion of stitchopenings, is highly air-permeable, does not give a warm sticky feeling,is able to maintain limbs in comfortable posture without slippage whenone sits on the cushioning surface, has soft touch feeling, is notglossy and has soft and quite natural fine appearance covered with finefibers and is not similar to monotonous simple surface of theconventional plastic goods in appearance, and has a high market value.

1. A warp knitted elastic fabric for a cushioning surface of a bodysupport characterized by the following elements: a base knitted fabricwarp knitted from main stitch yarns; main elastic yarns, of which singlefiber fineness is 1000 to approximately 4000 dtex and of which stress at10% elongation is more than 0.1 cN/dtex, knitted in the base knittedfabric in continuous line in a selected one of the knitting widthdirection and the knitting length direction; main inserted yarns knittedin the base knitted fabric in continuous line in a selected one of theknitting width direction and the knitting length direction; said maininserted yarns being more bulky than both said main elastic yarns andmain stitch yarns, and said main inserted yarns being visuallyapparently thicker as an observed value of the thickness of the yarnthan both said main elastic yarns and said main stitch yarns; and thesurface of the main inserted yarns being composed of multiple fibers,the total fineness of the main stitch yarn being less than one half ofthe total fineness of the main elastic yarn.
 2. A warp knitted elasticfabric for a cushioning surface of a body support as set forth in claim1, wherein: on the base knitted fabric, there are formed openings whichare larger than the needle loop formed from main stitch yarn and whichextend over plural knitting courses; and the base knitted fabric beingformed with a mesh surface configuration.
 3. A warp knitted elasticfabric for a cushioning surface of a body support as set forth in claim1, wherein the main inserted yarn is chenille yarn which is formed withaxis yarns and pile fibers for covering the axis yarns, and wherein saidpile fibers project from the axis yarns.
 4. A warp knitted elasticfabric for a cushioning surface of a body support as set forth in claim1, wherein the main stitch yarn is comprised of a thermo-adhesive sheathcore combination of polyether-ester yarn which is comprised ofpolyether-ester polymer applied to said core component polymer andthermo-adhesive polymer applied to said sheath component polymer whichhas a melting point being lower than the core component polymer.
 5. Awarp knitted elastic fabric for a cushioning surface of a body supportas set forth in claim 1, said main elastic yarn is comprised ofthermo-adhesive sheath core combination of polyether-ester elastic yarnwhich is comprised of polyether-ester elastic polymer applied to thecore component polymer and thermo-adhesive polymer applied to saidsheath component polymer which has a melting point lower than the corecomponent polymer.
 6. A warp knitted elastic fabric for a cushioningsurface of a body support as set forth in claim 1, wherein the finenessof plurality of the main elastic yarns which is included within a unitdistance in the knitting length direction or in the knitting widthdirection is more than 7000 dtex/cm.
 7. A warp knitted elastic fabricfor a cushioning surface of a body support as set forth in claim 1,wherein the main elastic yarn and the main inserted yarn are knitted incourses different from the courses of the based knitted fabric, the baseknitted fabric being knitted with plural courses per one repeat in theknitting length direction of the base knitted fabric.